Quick and easy programming, visualization, and diagnostics
The Smart Production Library for PLCnext Technology by Phoenix Contact enables companies to meet changing market needs, customized buyer demands, energy sustainability, and labor shortages through digitalization efforts. The library simplifies programming, visualization, and diagnostics in the engineering environment, making code generation and commissioning faster and easier.
Adapting to each application via drag-and-drop
The generator configuration file enables fully automatic visualization creation. The library includes functions for diagnostics, operating modes, and various technologies. The HMI web server handles visualization without data storage on display devices. Function blocks combine logic, visualization, and diagnostics, simplifying configuration. The interface features generic animations, easily customizable by adjusting parameters. The library supports extensions, drag-and-drop objects, and multiple languages.
The Library is divided into three functional areas: Basic functions, Operating mode functions, and Technology functions.
Basic functions: Diagnostics of the controller and client access control, including exclusive mode and alarm management.
Operating mode functions: Support for various operating modes and safety features.
Technology functions: Control for actuators, sensors, and energy measuring devices, with the ability to add more technologies as needed.
Creating visualizations in just a few minutes
A clear application program structure aids visualization generation. The HMI generator features two methods: a comprehensive overview and selective visualization for stations. It quickly creates visualizations, saving time. Changes are immediate, ensuring error-free operation and consistent data management between PLCnext Engineer and the PLC.
Cloud integration via app from the PLCnext Store
The Smart Production Library is part of the PLCnext Technology ecosystem, enabling the integration of standard PLC programming with high-level languages for real-time execution. Cloud connection is facilitated through apps like “Node Red for PLCnext,” ensuring system availability without impacting automation processes.
Greater efficiency and time savings of 60 percent for wire and cable identification
The Thermomark E Series marking system combines printing and application in one step, saving approximately 60% of the time in industrial marking tasks. It improves efficiency by enabling clear and uniform marking of components throughout the product lifecycle of a control cabinet. The system reduces the previously time-consuming process of printing, separating, and mounting markings on cables, wires, and components. It enhances safety and simplifies workflows with visible and permanent identification.
Automated identification
The Thermomark E Series marking system by Phoenix Contact automates printing and applying of marking materials in a single step, resulting in 60% time savings. It offers an efficient and user-friendly identification process with high-quality markings, improving longevity and durability.
Modular marking system
The Thermomark E Series is a modular marking system with applicators connected to a thermal transfer roll printer. It offers flexible wire and cable identification solutions without additional devices, saving resources and space.
Efficient wire and cable identification
Thermomark E Series provides three applicators for automated wire and cable identification. The E.Wire creates movable cable markers, the E.Sleeve processes shrink sleeves, and the E.Wrap applies wire-wrap labels. Each applicator offers specific features for efficient and precise marking based on different cable diameters.
Seamless software-supported marking processes
Standard IEC 61439 requires clear and permanent identification of devices in control cabinets. The marking software by Phoenix Contact allows for efficient data import from digital circuit diagrams, enabling the automatic transfer of marking information. Intuitive functions facilitate wire and cable identification, reducing errors. The Marking System software provides an overview of the project, guiding users through the identification process. The information can be displayed on a separate monitor or the Thermomark E Series device.
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Protection and supply – the intelligent way: The communicative 24 V supply system with everything in view
The power supply is vital for control cabinets as it provides power to 24 V components. In industries where system availability is crucial, the Quint Power 24 V supply system from Phoenix Contact offers communication capabilities, increasing data transparency and system availability. Operators can access operating and diagnostic data to monitor the network and optimize costs through preventive function monitoring.
Raising optimization potential – maximum system transparency for maximum availability
Data collection is essential for system availability. The Quint Power communicative power supply from Phoenix Contact offers two options: connecting to the Caparoc fuse via a proprietary data bus or using the IO-Link interface to connect to an automation system. Both options allow for data transmission and monitoring of power supply and UPS system data.
Monitoring and parameterization
The Quint4 power supply ensures complete data consistency, enabling early warning of malfunctions. It offers targeted maintenance, remote diagnostics, and cost savings. Data collected includes remaining service life and network surges, aiding preventive maintenance. Fieldbus interfaces and a web server provide system transparency. Parameter configuration is easy, avoiding user errors. Centralized configuration saves time and costs.
Integrated phase monitoring
The Quint4 communicative power supply with IOL interface features integrated phase monitoring, providing information on three-phase availability. It can run at full power on two phases and constantly monitors rotating field direction and input voltage.
Power supply and electronic circuit breaker system grow to become a single system
The Quint Power communicative power supply combines with the Caparoc circuit breaker system for monitoring fuse channel characteristics. It enables preventive maintenance, accurate remote maintenance, and cost savings. The system offers automatic configuration and optimization based on operating data, simple integration, and complete data consistency.
The communicative 24 V supply system from Phoenix Contact allows for monitoring load currents and operating temperature, providing optimal system monitoring. It enables preventive measures to be taken, reducing downtime and optimizing costs. The system offers extensive data for maintenance and early warnings for heavy equipment utilization.
Phoenix Contact is taking steps to maximize energy production by implementing new processes. Firstly, installing lightweight modules on buildings. Moreover, these films, weighing only three kilograms per square meter, directly adhere to the roof surfaces. Additionally, with their specialized surface design, they optimize light refraction and achieve energy yields comparable to standard modules. This approach not only increases efficiency but also reduces the amount of mounting material required.
Combination of conventional and flexible modules
Phoenix Contact is implementing a mix of conventional and flexible modules in its photovoltaic systems. Building 34 will have lightweight modules generating 750 kWp, while Building 60, currently under construction in Blomberg, will use conventional modules only with over 1,000 kWp capacity. They aim to install solar systems across all German sites by 2030. Their international subsidiaries in the USA, China, Austria, and India are also expanding their solar initiatives
Weather station for calculating the performance ratio
Phoenix Contact offers a range of components and solutions for cost-effective operation of photovoltaic systems. The string combiner boxes provide protection and efficient distribution of DC currents. They use weather stations to evaluate system performance and make adjustments as needed.
Grid stability by using certified power control units
Phoenix Contact utilizes in-house data loggers to collect and analyze data from their photovoltaic systems. These loggers connect various system components for easy data integration and storage. Additionally, their power control unit ensures grid compliance by monitoring voltage and reactive power and adjusting inverters as needed. Compliance with certified feed-in controllers is mandatory for larger photovoltaic systems since 2018.
Amortization after one-third of the service life
Phoenix Contact’s photovoltaic systems will have a total output of around six megawatts, meeting 5.5 percent of their electricity demand. Solar power proves to be cost-effective, with production costs one-third of procurement costs. This aligns with their climate neutrality strategy and vision for an All Electric Society. The photovoltaic systems are expected to pay for themselves within one-third of their service life.
The choice of the right connection technology is crucial for seamless processes in automation and digitalization. Reliable data transmission is essential, and selecting high-quality components is paramount. Low-cost options often lead to errors and costly repairs. Phoenix Contact offers specialized RJ45 patch cables for different application areas, ensuring reliable data transmission and compliance with required properties. Choose the right components for optimal efficiency and value in operations.
Ensuring Reliable Data Transmission for Efficient Processes
Automation, digitalization, and Industry 4.0 rely on consistent data acquisition and transmission. The choice of the transmission medium is critical for reliable data processing and control. Increasing data volumes require effective collection and analysis. Sensors generate data, while actuators utilize it to control systems. Selecting the right transmission medium is essential for seamless data transfer.
The wrong choice weighs heavily
Proper component selection is crucial for seamless data transmission. Choosing low-cost, low-quality options can lead to errors and costly repairs. Copper is commonly used as a transmission medium, but caution is needed to avoid unreliable products. Selecting high-quality cables designed for specific applications is essential for smooth processes and successful operations.
Choosing the right component
Phoenix Contact offers a clear portfolio of RJ45 patch cables for different application areas. The top line is the RJ45 Industrial patch cable, designed for demanding industrial environments. It features robust connectors, mechanical stability, 360° shielding, and the trustworthy transfer of data. for various protocols and speeds. They also offer variants for less demanding applications, ensuring reliable transmission while meeting specific requirements.
Fighting the climate crisis with series production
Power-to-X is a vital part of the energy revolution, aiming to replace fossil fuels with renewable sources. It involves converting renewable electricity into gases, chemicals, or fuels. PtG methods, particularly important for sector coupling, utilize existing gas infrastructure for storage and transport. The “European Hydrogen Backbone” envisions repurposing and expanding the infrastructure for hydrogen transportation. Automation and electrification strategies, such as Enapter AG’s AEM electrolyzers, are crucial for cost-effective and safe conversion processes. The installation of more wind and solar systems will further drive the transition to cleaner energy.
Interconnection of numerous electrolyzers to create gigawatt plants
Germany is witnessing an increase in PtG plants, using various electrolysis methods and reaching several megawatts of power. Plans for 100 MW plants are underway in Lower Saxony. Projects in Neom and Rotterdam will utilize gigawatt-scale electrolyzers. Germany aims to create 10 GW of electrolysis capacity by 2030. Green hydrogen is converted back using fuel cells or chemically into substances like ammonia or methanol. Automation and communication strategies are crucial for all processes, from hydrogen generation to consumption.
Manufacturing containers based on the industrial model
Manufacturers are developing containerized electrolyzers for hydrogen production, allowing for modular and interconnected gigawatt-scale plants. Industrial manufacturing methods enable efficient mass production of these containers. Providers like Phoenix Contact offer connection and automation technology, assisting with component selection and providing engineering and design services. Enapter AG’s AEM Multicore electrolyzer system uses an ion-conducting membrane and a cheaper catalyst, allowing for cost-effective hydrogen production with renewable electricity.
Supply of ready-to-use control cabinets based on PLCnext Technology
Enapter’s scalable AEM Multicore solution consists of interconnected stack modules in a container, producing up to 450 kg of hydrogen per day. Phoenix Contact provides control technology and DC power supply for the electrolysis stacks, including ready-to-use control cabinets. The container control room monitors hydrogen production, tank levels, and safety measures. Phoenix Contact’s PLCnext Technology handles control tasks and supports maintenance concepts. The control cabinets incorporate Ex protection components for hazardous areas.
Implementation of safety-related applications up to SIL 3
Phoenix Contact’s automation solution allows for safety-related applications up to SIL 3 in electrolysis plants. They offer cost-effective options, such as extending the PLCnext Control with an SIL 3 module. Their safety portfolio includes power supply units, relays, and motor starters. Comprehensive solutions for DC power electronics, like Charx Power modules, are available. The use of electrical connectors improves assembly efficiency and reduces costs. Phoenix Contact provides a wide range of products to support the scaling of hydrogen production in Germany.
Consultation in all phases of the lifecycle
Phoenix Contact offers consultation services for various aspects of plant development. They help determine cooling capacity, assess safety integrity levels, and provide assistance with technical specifications, safety software implementation, and testing. Their consulting service covers control cabinet building, including CE marking, EMC, explosion protection, and access protection.
Communication solutions in all directions
Phoenix Contact supports communication and integration in power-to-X applications. They assist with the dynamic operation and functional integration of electrolyzers with power generation and consumption areas. They provide solutions for fuel cells as emergency power systems and offer support for remote control, maintenance, data collection, and digital twin implementation. Their portfolio includes products for reliable and secure data transmission. Phoenix Contact’s certified products ensure IT security. They are also developing software modules for future use, enabling newcomers to create their own software applications in the power-to-X industry.
MTP as the basis for modular solutions
Phoenix Contact supports the implementation of large modular electrolysis plants for green hydrogen production. They facilitate scalability and reduce implementation effort through the use of standardized MTP (Module Type Packages) interfaces, allowing for modular automation solutions.
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Marmo NV, a meat processing company in Belgium, focused on energy efficiency when renovating its refrigeration system. They partnered with Sabcobel, an experienced cooling systems company, who chose Phoenix Contact’s speed starters for fan speed regulation. The renovated system utilized CO2 as the evaporating refrigerant minimized refrigerant quantity and repurposed residual heat for hot water generation. Sabcobel’s expertise in creating cold chains for the food industry ensured a successful installation at Marmo.
Compact design saves space in control cabinets
Marmo has 60 chillers in their production area, each with a specific setpoint controlled by a system. Phoenix Contact’s speed starters regulate the three-phase AC fans’ speed, ensuring employee comfort and consistent temperatures. The system includes an air boost function in each room, allowing employees to increase air speed when needed. This flexible fan speed control system prioritizes energy efficiency while enhancing comfort. The compact design of the speed starters was a key factor in their selection, as they require minimal space in the control cabinet. These modules offer functionalities that bridge the gap between motor starters and frequency converters, operating on three-phase power with a maximum power rating of 1.5 kilowatts.
Flexible I/O system for connecting the chillers to the central PLC
The refrigeration system at Marmo is efficiently controlled by a central PLC unit connected to distributed I/O islands through the Profinet protocol. This setup offers cost savings and improved efficiency.
The system includes 11 distributors responsible for controlling the 60 chillers in various rooms. These distributors are connected to the central PLC using the Profinet network. To manage the I/O islands effectively, Marmo opted for the Axioline Smart Elements I/O system from Phoenix Contact. This choice was driven by the system’s compact design and flexibility. The installation incorporates a significant number of digital and analog inputs and outputs, including RTD cards for temperature sensors, pressure measurement, and gas detection. The use of Smart Elements modules on a backplane enables seamless communication via Profinet network.
furthermore, one notable advantage of the distributed I/O system is its transparency to the central PLC. This simplifies the management and monitoring process for the system, making it easier to control and maintain.
Remote monitoring for in-service support
Implementing the new refrigeration system during production was a challenge, but the user-friendly Smart Elements modules with Phoenix Contact’s tool-free Push-in connection technology proved beneficial. Also, Maintenance Manager Tim Steegmans appreciated Sabcobel’s support and the system’s industrial approach for operational reliability. Remote monitoring and remote reset capabilities in speed starters enabled efficient assistance from Sabcobel’s specialists.
Find out more about the new standards on our webpage.
Energy storage systems are key to an All Electric Society. Ensuring a stable energy supply by compensating for the volatility of renewable energy sources. This report looks at the typical design of a battery system storage system. Furthermore, exploring the flow of energy and information between the various components. Discover how electrical connection technology can ensure reliable storage systems and support a successful transition to an All Electric Society.
Typical energy storage system design
Electric energy storage systems based on galvanic batteries can be applied to a variety of sizes, from multi-megawatt-hour systems to small home systems of 10 kilowatt-hours. Battery cells are connected in parallel or series to form packs, and welding technologies are used to create permanent electrical connections. This modular design is adjustable and has only a few limitations.
The battery module
Storage modules house large numbers of cells and are monitored and controlled by a Battery Management System. The BMS measures and sets the voltage and current of cell groups for uniform charging/discharging (balancing), and provides power and data connections from the BMS PCBs to the module housing (usually with screw connections for power and plug-in concept for data).
Industrial 5G, the next generation of wireless technology, will provide reliable, high-speed, and low-latency connections for a large number of users. This will enable flexible, autonomous, and efficient processes from production to logistics in the future.
What exactly is Industrial 5G?
5G is the latest cellular standard offering high bandwidth, real-time capability, high reliability, security, and support for large numbers of users.
Basically, 5G is the first cellular generation to satisfy industrial sector demands, enabling intelligent wireless communication between machines and applications. Besides, enables private networks for flexible, sustainable network connections in mobile or highly flexible applications.
Industrial 5G is the perfect technology for Industry 4.0. It provides high levels of flexibility, usability, and efficiency that will enable smart factories and the IIoT.
5G technology’s features and characteristics
Industrial 5G provides higher performance than earlier cellular standards, with features like low latency (ultra-reliable low-latency communication, URLLC), high connection density (massive machine type communication, mMTC), and bandwidth (enhanced mobile broadband, eMBB), as well as comprehensive IIoT connectivity and greater flexibility.
Industrial 5G enables customized properties to be assigned to each application, granting specific resources in a private network. This provides a triangle of functions, delivering enhanced flexibility and control.
In the future, it will be possible to create consistent private 5G networks for specific applications. These applications will replace the current mix of wireless and wired technologies (e.g. WLAN, WirelessHART, GSM, LTE).
